INSTALLATION MANUAL - Solar Photovoltaics
Contents
1. 2 5 5 1 Stainless steel M8 nut 1 2 Stainless steel serrated washer I _ 3 Aluminum clamping plate 7 c 4 EPDM washer 2 mm 0 78 in _C D 5 Stainless steel M8 T head bolt T H z __ 3 ait Figure 2 60MC I Module Physical Dimensions 1013 QO 4 4 O 30882 pom FRAME N lt gt 5 7 gt 0512 p r 40 4 q 1 591 v F L on A lt gt 4 4 1650 ri 1000 10 3937 00533 642p 980 q 38 583 Ne Weight 22 5 kg It is recommended that a torque wrench be used for installation In Figure 1 j SOR Example A the tightening torque using stainless steel M8 bolts should be ie oa approximately 15 20 Nm 11 15 ft Ib Use the existing holes for securing the seis module Do not drill additional holes as doing so would void the warranty Use 3 o i appropriate corrosion proof fastening materials j Each module must be securely fastened at a minimum of 4 points The frame FRAME Wiii a has been stress tested for mounting on the long sides The module must not be F secured by its short sides This method offers maximum loading capacities on ry yy the module surface See Figure 2 a The support points of the mounting racking profiles on which the modules are fastened e g by means of clamp connections must correspond in the distance to each other to the position of the2. A DAY4 ENERGY INSTALLATION MANUAL Manufactured by Day4 Energy Inc 401 4621 Canada Way Burnaby BC Canada V5G 4X8 office 1 604 297 0444 fax 1 604 297 0445 email info day4energy com web www day4energy com This manual applies to the following products Day4 Energy 36MC 48MC 48MC S and 60MC I Please read and study this manual completely before installation or use of any Day4 Energy Inc Day4 Energy photovoltaic modules Refers to instructions for Refers to instructions for Europe installations only USA and Canada installations only gt Refers to instructions for Refers to instructions for sy 36MC 48MC amp 48MC S modules only 60MC I module only INTRODUCTION With proper installation operation and maintenance Day4 Energy modules will provide you with clean renewable solar electricity for many years This manual contains important installation maintenance and safety information Retain this manual for future reference The word module s as used in this manual refers to one or more Day4 Energy 36MC 48MC 48MC S and 60MC photovoltaic modules Disclaimer of Liability Day4 Energy does not assume responsibility and expressly disclaims liability for loss damage or expense arising out of or in any way connected with installation operation use or maintenance by using this manual Day4 Energy assumes no responsibility for any infringement of patents or other rights of third parties which may res
3. Energy module will not be accepted by Day4 Energy unless prior written authorization has been given by Day4 Energy As part of our policy of continuous improvement Day4 Energy reserves the right to change product specifications at any time without prior notice and at its sole discretion 101310 A4 EN SPECIFICATIONS Notes on Specification e Rated electrical characteristics are within 3 5 of the values measured at Standard Test Conditions STC STC are Irradiance of 1000 W mz2 25 C cell temperature and solar spectral irradiance per IEC 60904 3 AM1 5 solar spectral irradiance The current output for the Day4 Energy modules is shown in the Specifications as measured at Standard Test Conditions These conditions may not be frequently observed in actual practice Under normal conditions a Day4 Energy module may experience conditions that produce more current and or voltage than reported at Standard Test Conditions Accordingly the values of Isc and Voc marked on listed module should be multiplied by a safety factor of 1 25 when determining voltage ratings conductor capacities fuse sizes and size of controls connected to the module output Electrical ratings at STC Maximum system voltage rating ica Europe IEC 61215 1EC61730 rating 1000V wy USA and Canada UL 1703 rating 600V Day4 36MC Series Modules Pmax Maximum Maximum Short Circuit Open Circuit Umpp Impp Power Voltage Power Curren
4. install Day4 Energy modules above flammable material Special attention needs to be paid when Day4 Energy modules are installed as building integrated product BIPV Do not remove the frame or parts thereof Do not run reverse current through a Day4 Energy module in an attempt to de ice the module or for any other purpose Do not stand or walk on the surface of a Day4 Energy module as you may cause damage to the frame or other parts of the module CAUTION Use a Day4 Energy module for its intended purpose only Please refer to the Day4 Energy 36MC 48MC 48MC S and 60MC series warranty document To avoid reduced module functionality damage inoperable conditions and other unknown troubles do not treat the backsheet or front surface with paint or adhesives Do not disconnect connectors under load GENERAL SAFETY Follow all permission installation and inspection requirements Before installing Day4 Energy modules contact the appropriate authorities to determine permissions installation and inspection requirements to be followed Electrically ground Day4 Energy modules for all systems of any voltage mandatory in USA and Canada recommended in Europe If not otherwise specified it is recommended that requirements of the latest National Electrical Code USA or Canadian Electric Code Canada or any other applicable national or international electrical standards be used fe hig Be sure that the construction
5. or structure roof facade etc where the Day4 Energy modules are being installed has enough strength to support the added module and structure weight For modules that are to be mounted on roofs special construction or structures may be required for proper installation Both roof construction and module installation design have an effect on the fire resistance of a building Improper installation may contribute to fire hazards Additional devices such as ground fault fuses and disconnects may be required Do not use Day4 Energy modules of different specifications power class size etc in the same system Follow all safety precautions of other system components used Do not change or alter Day4 Energy modules or apply improper means such as but not limited to mirrors and or other optical systems of any kind Do not operate the modules under artificially concentrated sunlight such as an optical system and or in direct contact with solar thermal systems UL Listing Information applies to USA and Canada only To satisfy UL requirements when installing Day4 Energy modules be sure to 1 Use only stranded single conductor wire of listed type USE 2 12 AWG rated 90 C 600 V sunlight resistant for Day4 Energy modules and interconnect wiring that is exposed to weather 2 Observe the requirements described in sections of this manual labeled INSTALLATION and SPECIFICATIONS 3 Grounding of the Day4 Energy module frame
6. pre installed mounting holes on the module R i frames with a divergence of maximum 100 mm amp 48MC S Module Physical Dimensions In Europe only Day4 Energy modules have been evaluated by 9915 MODULEERAME third party testing for a maximum positive design loading of 39 035 B 5400 N m and a maximum negative design load of 2400 N m 7 I 0512 In Europe only Day4 Energy modules have been evaluated b for mounting using a clamp on or a bolting technique i 40 2 refer to Figure 1 Example A and B i I sie 1583 e In USA and Canada only Day4 Energy modules have been evaluated by Qo 51 476 UL for a maximum positive or negative design loading of 1436 4 N m i KR 30 Ibs ft2 EE 925 10 30 In USA and Canada only Day4 Energy modules have been evaluated for 36 42 0393 501 1 181 mounting using a bolting technique refer to Figure 1 Example B q EE Ne 653 5 25 728 16 0 kg Y 1 35 2 Ibs d 403 DRAINAGE 6o 15 867 Millimetres Ei Z ou Inches 947 37 283 4 04 denotes 4 holes grounding holes centered on each edge with a diameter DAY4 ENERGY of 4mm Grounding Hole 4 99 denotes 4 holes mounting holes with a diameter of gmm Specifications and design are subject to change without notice The features functions and appearance of Day4 MC modules may differ from details given due to continual product development For updated NOTE All dimensions are accurate within 1 5mm tolerance unless otherwise st
7. ALLATION Figure 1 Example B 4 Do not apply any external voltage higher than Voc labeled on the module 5 Refer to the module label for maximum series fuse rating 101310 A4 EN INSTALLATION General Please read this guide completely before installation or use of Day4 Energy modules This section contains electrical and mechanical specifications needed before using your modules Day4 Energy modules should be firmly fixed in place in a manner suitable to withstand all expected loads including wind and snow loads Do not drill additional mounting holes into module frames as this will void the warranty Day4 Energy modules must not be fitted as overhead or vertical glazing Day4 Energy modules must be installed in a way that ensures the junction box is in the uppermost position The appropriate material should be used for mounting hardware to prevent the module frame mounting structure and hardware itself from corrosion Install Day4 Energy modules where they are not shaded by obstacles like buildings and trees Pay attention to avoid partial shading by objects during the daytime Do not operate the module if it is shadowed or otherwise covered in its entirety or partially by debris leaves tree branches dirt bird droppings snow ice and or any other substance or objects capable of preventing the light from illuminating the front surface of the module in a uniform unobstructed manner refer to section in this
8. The Day4 Energy modules can be used for off grid installations like charging batteries if electronic equipment such as a power tracker is used to control module output parameters and provides accurate electrical output according to off grid appliance specifications Please contact your local licensed installer regarding the use of Day4 Energy modules in off grid applications and in combination with charge controllers or similar equipment Day4 Energy modules contain factory installed bypass diodes If these modules are incorrectly connected to each other the bypass diodes cables or junction boxes may be damaged Array Wiring The term array is used to describe the assembly of several Day4 Energy modules on a support structure with associated wiring Use insulated copper wire that is suitable for outdoor use and is insulated to withstand the maximum possible system open circuit voltage Check local codes for further requirements 101310 A4 EN Earth Ground Wiring Ground should be carried out by securing the Day4 Energy module or array frame to avoid the hazards of electric shock or fire The array frame should be grounded in accordance with NEC Article 250 USA Installations in Canada shall be in accordance with CSA C22 1 Safety Standard for Electrical Installations CEC part 1 Contact local authorities to determine the necessary grounding code requirements Proper grounding is achieved by connecting the module frames
9. and structural members contiguously together using a suitable grounding conductor It is recommended to utilize a UL listed grounding lug made of stainless steel Use a tin plated or beryllium 1 grounding lug if the grounding g method involves attachment of U a grounding lead to the module frame A The grounding conductor grounding lead or strap may be copper copper alloy or another MODULE FRAME A Ilsco Model GBL 4DB Ground Lug material acceptable for use as an electrical conductor per NEC CEC 1 6 32 stainless steel nut The grounding conductor must 2 6 stainless steel star washer make a connection to earth using 3 6 stainless steel washer a suitable earth ground electrode Ensure positive electrical contact through the anodizing on the module s frame by utilizing one of the following grounding methods 4 6 32 stainless steel screw Attach the grounding conductor 1 To one of the 4 mm 0 16 in holes marked ground with a nut bolt or screw assembly and a serrated washer external toothed washer or a paint piercing washer for attachment of the grounding lug to the Day4 Energy module frame 2 To electrically conductive metal such as that of a support structure which has been bonded to the module frame through a bonding or external tooth washer or a welded or a soldered for brazed joint or other suitable means as described above 3 With two or mor
10. ated Product documentation please contact Day4 Energy Inc or check our website www day4energy com dimensions in imperial inches conversion of 1mm equals 0 03937in 1kg equals 2 2lbs are provided for information purposes only 101310 A4 EN 5
11. censed professional should attempt to open the cover of the junction box To avoid the risk of electric shock or injury employ suitable clothing and tools to prevent direct contact with solar electric systems with voltage greater than 40V Use caution when carrying Day4 Energy modules It is recommended that two or more persons carry the module by its frame and use non slip gloves Do not carry a Day4 Energy module by its connecting wires or junction box Do not drop anything on the surface of a Day4 Energy module A damaged surface can cause electric shock and injury To avoid the hazard of electric shock and fire be sure that all system components are compatible with Day4 Energy modules Components should not subject the module to mechanical or electrical hazards Since sparks may occur do not install the Day4 Energy module where flammable gases or vapors are present Never leave a Day4 Energy module unsupported or unsecured especially on elevated places of installation like roofs buildings and on scaffoldings Do not drop a Day4 Energy module Do not use or install a broken or damaged Day4 Energy module Day4 modules with damaged back sheets should never be installed or operated To avoid the risk of fire or damage do not artificially concentrate sunlight on a Day4 Energy module Do not touch the junction box terminals This can cause electric shock and injury Do not change the wiring of bypass diodes Do not
12. e screws or two full threads of a single screw engaging the module frame metal Attention Do not allow dissimilar metals such as copper and aluminum to come in contact with each other Use grounding lugs made of stainless steel beryllium or tin plated Never use self tapping screws to connect the grounding conductor Day4 Energy Module Terminations A junction box as a terminal enclosure is equipped for electrical connections on Day4 Energy modules Day4 Energy modules are equipped with industry proven interconnection systems in either UL or IEC compliant versions output cables and male and female cable couplers Use the couplers for electrical connections only Please refer to module data sheet and contact your Day4 Energy authorized representative with questions regarding electrical connections for Day4 Energy modules Junction Box and Terminals Day4 Energy modules are equipped with one junction box with terminals for both positive and negative polarity and bypass diodes One terminal is dedicated to each polarity with the polarity symbols engraved onto the terminals or junction box No modifications to the junction box are permitted Conduit For applications where wire conduits are used follow the applicable codes for outdoor installation of wires in conduits Verify that all fittings are properly installed to protect wires against damage and prevent moisture intrusion STANDARD OPERATING CONDITIONS It is recommended t
13. hat Day4 Energy modules be operated under STANDARD OPERATING CONDITIONS SOC An installation location with conditions different from SOC or with other SPECIAL CONDITIONS see below should be avoided SOC of Day4 Energy modules are as follows 1 Standard Operating Conditions The Day4 Energy module should be operated only in terrestrial applications No space or other SPECIAL Conpitions see below The operating temperature of the module should be within 35 C 31 F to 90 C 194 F The relative humidity should be within 45 to 85 Installations have to be carefully reviewed in regards to wind loads Appropriate installation methods must be used If wind loads higher than 2400N m are expected contact Day4 Energy for further information 2 Special Conditions Operating temperature and installation place conditions are different from SOC The salt damage is extreme at the installation location The local climate generates snow accumulations heavier than 2400N m for extended periods of time which are not regularly removed by authorized personnel The local climate generates hail storms with hailstones larger than 20 mm in diameter The local climate generates sand and dust storms on more than three days year The air pollution chemically active vapors acid rain soot or other pollutants are extreme at the installation location In areas with higher than normal concentration of gase
14. is required When ground wires greater than 6 mm No 10 AWG are required the installer will need to provide suitable terminal connectors IEC 61730 Application Class A Information applies to Europe only Day4 Energy modules are designed to pass the criteria of application class A requirements according to IEC 61730 part 1 To satisfy IEC 61730 requirements when installing the Day4 Energy modules be sure to aa Use only double insulated stranded copper type cable The cable should be resistant to UV water ozone fluids salt general weath ering and abrasion The cable should be halogen free and flame retardant for the Day4 Energy module and interconnect wiring Be sure the cable is certified according to IEC 60228 class 5 N Observe the requirements described in sections of this manual labeled INSTALLATION and SPECIFICATIONS Equipotential bonding of the Day4 Energy modules and module frame is recommended The equipotential bonds between modules may only be connected and approved by a qualified electrician w Option 1 Connect the module frame using cables 16 mm 0 64 in2 with cable lugs Use the holes diameter 4 mm 0 16 in for this purpose To create the conductive connection frame is anodized use a self tapping screw diameter 5 mm 0 20 in ora serrated washer Option 2 Create an electrical connection between the frames and the mounting system by using serrated lock nuts see INST
15. ized Day4 Energy representative for the proper diode type if it is necessary to add or change diodes due to system specifications WIRING General All wiring methods should be in accordance with the NEC in USA or CEC in Canada or any other code electrical code law or bylaw applicable for the place of installation All wiring should be completed by a qualified licensed professional Wiring should be protected to help ensure personal safety and to prevent damage All Day4 Energy modules connected in series should be of the same model class and or type Do not connect Day4 Energy modules in parallel without using a connection box Cable used for any wiring should be sized according to applicable electrical codes Any cable used in the installation should conform to the requirements of IEC 60228 class 5 Europe only ie Day4 Energy Module Wiring The maximum number of Day4 Energy modules that can be wired in series or parallel design is dependent on legal requirements maximum current and voltage ratings as indicated on the module label installation design space and further specifications of additional equipment such as inverters and converters Day4 Energy modules must have the same amperage when connected in series When connected in parallel the modules must have the same voltage The modules must not be connected together to create a voltage higher than the permitted system voltage according to protection class A
16. manual labeled NOTES ON INSTALLATION d Do not permanently operate the module if it is shadowed or otherwise covered in its entirety or partially by debris leaves tree branches dirt bird droppings snow ice and or any other substance or objects capable of preventing the light from illuminating the front surface of the module in a uniform unobstructed manner refer to section in this manual labeled NOTES ON INSTALLATION gt Please contact your Day4 Energy authorized representative with questions regarding mounting profiles for modules Notes on Installation Clearance between the Day4 Energy module frame and the mounting surface is required to allow cooling air to circulate around the back of the module This also allows any condensation or moisture to dissipate The module should never be sealed to the mounting surface with sealant preventing air from circulating under the module In Europe only The recommended distance is minimum 50 mm In USA and Canada only In order to maintain UL Listing a minimum clearance of 10 16 cm 4 in is required between module and any installation surface A minimum slope of 5 inch ft for installations over a roof is required to maintain the fire class ratings In order to determine the maximum annual yield the optimum orientation and tilt of the Day4 Energy modules must be identified Sunlight shining vertically onto the modules will give the best conditions to generate ma
17. odule produces only a low voltage and current shocks and burns are still a potential risk To avoid the danger of electric shock and injury cover the front glass surface of the Day4 Energy module with a dense opaque material during installation and handling The shock hazard increases as Day4 Energy modules are connected in parallel producing higher current The shock risk increases as modules are connected in series producing higher voltages To avoid the peril of electric shock work only under dry conditions with dry modules and tools To avoid the risk of injury and damage to the module do not stand or step on a Day4 Energy module To avoid the threat of electric shock and or fire do not puncture or damage the backsheet of a Day4 Energy module To avoid the peril of electric shock and injury children and unauthorized persons should not be allowed near the installation of modules In Europe grounding is recommended for Day4 Energy modules In USA and Canada it is a requirement to completely ground all Day4 Energy modules fe ak 101310 A4 EN To avoid the danger of electric shock fire and injury do not disassemble the Day4 Energy module or remove any part installed by Day4 Energy or any authorized dealer or integrator Unauthorized persons should not open the cover of the junction box as this increases chances of dangerous electric shock may cause damage to the module and will void the warranty Only a qualified li
18. s like CxHy NH3 H2S Day4 Energy shall be consulted upon special installation requirements not covered by this installation manual MAINTENANCE Some maintenance is recommended to maintain optimal output performance of the Day4 Energy modules If the module surface becomes dirty it may reduce output power It is recommended to clean the surface of the module with plenty of water and a soft cloth or sponge A mild non abrasive detergent may be applied for persistent dirt Never scratch or rub away any dirt when dry Do not use a high pressure cleaner or automated cleaning equipment It is also recommended to inspect the Day4 Energy module s electrical and mechanical connections annually All fastenings should be tight and secure and free of corrosion All cable connections should be secure tight clean and free of corrosion Cables may not be damaged in any way Take care that the lid of the junction box is tightly secured and electrical connectors are properly connected and free of corrosion To avoid the risk of electric shock and or injury it is recommended an authorized professional carry out the electrical and or mechanical inspection and or maintenance is required If modules are stored prior to installation ensure that no water dirt dust etc accumulates on the module s back side The contacts and the junction box especially must be kept free of any moisture Inside storage is strongly recommended The return of any Day4
19. t Current Voltage w v A A v 115 16 80 6 89 7 60 20 98 120 16 95 7 08 7 70 21 23 25 17 21 7 30 7 90 21 52 30 17 55 7 46 8 05 21 90 35 17 78 7 60 8 10 22 05 140 17 98 7 19 8 20 22 28 45 18 24 7 95 8 30 22 57 Day4 48MC Series Modules Pmax Maximum Maximum Short Circuit Open Circuit Umpp Impp Power Voltage Power Current Current Voltage w v A A v 155 22 30 6 97 7 55 28 00 160 22 60 7 08 7 70 28 30 65 22 95 719 7 80 28 60 70 23 04 7 38 7 90 28 80 175 23 40 7 48 8 05 29 20 180 23 70 7 60 8 10 29 40 185 23 82 7 17 8 20 29 51 90 24 00 7 92 8 30 29 70 95 24 24 8 08 8 40 29 94 Day4 60MC Series Modules Pmax Maximum Maximum Short Circuit Open Circuit Umpp Impp Power Voltage Power Current Current Voltage w v A A v 205 28 42 7 22 7 13 35 41 210 28 69 7 33 7 84 35 75 215 29 08 7 41 7 92 36 03 220 29 36 7 51 8 05 36 23 225 29 47 7 62 8 12 36 48 230 29 52 7 80 8 32 36 71 235 29 77 7 89 8 42 37 90 240 30 03 7 98 8 54 3712 245 30 29 8 08 8 58 37 32 250 30 55 8 17 8 64 37 54 USA Refer to Section 690 8 of the U S National Electrical Code for an additional multiplying factor of 1 25 which may be applicable Figure 1 1 Q CLAMPING ON
20. ult from the use of Day4 Energy modules No license is granted by implication or under any patent or patent rights The information in this manual is believed to be reliable but does not constitute an expressed and or implied warranty Day4 Energy reserves the right to make changes to the product specifications or manual without prior notice and on its sole discretion General Information The installation of photovoltaic Day4 Energy modules requires a great degree of skill and should only be performed by qualified licensed professionals including without limitation licensed contractors and licensed electricians WARNING Allinstructions should be read and understood before attempting to install wire operate or maintain the photovoltaic Day4 Energy module Contact with electrically active parts of the module such as terminals can result in burns sparks and lethal shock whether the module is connected or disconnected Some transformer less inverters are not suitable for use with photovoltaic modules in specific applications Check with the inverter manufacturer the inverter installation manual and attain the inverter manufacturer s approval prior to use The installer assumes the risk of any injury that might occur during installation including without limitation the risk of electric shock and or fire Day4 Energy modules generate DC electrical energy when exposed to sunlight or simulated sunlight sources Although a single m
21. ximum power To avoid performance drops in series circuits ensure all modules have the same orientation and tilt Modules should be of the same power class Even the slightest partial shading like from dirt deposits will cause a reduction in yield A module is considered shadow free if it is un obscured across its entire surface for the entire year Even on the shortest day of the year un obstructed sunlight should reach the module The recommended standoff height minimum to satisfy the UL fire class C rating is 10 16 cm 4 in Other mounting methods will affect the fire class rating The fire class rating of the PV module installation must meet the code requirements as well as the requirements of the specific place of installation e Please refer to Figure 1 and Figure 2 for proper installation DIODES Bypass Diodes Day4 Energy modules in series strings that are partially shaded may cause reverse voltage across cells or modules because current from other cells in the same series is forced to flow through the shaded area This may cause undesirable heating to occur The use of a diode to bypass the shaded area can minimize both heating and reduce the array current All Day4 Energy modules are equipped with factory installed bypass diodes The factory installed diodes provide proper circuit protection for the systems within the specified system voltage so that no other additional bypass diodes are required Contact your author
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